The Connected Industrial Enterprise:

InsideNetworks vs. Protocols

Machine Security

Water Plant Improves Performance Efficiency

Machine Builders ImproveEquipment Performance

AutomationTODAY ASIA PACIFIC

Australia & New Zealand

AutomationJanuary 2015

The Connected Industrial Enterprise:Optimised to Create ValueSee page 6

CONTENTSEDITORIAL

Automation Today is published byROCKWELL AUTOMATION SOUTHEAST ASIA PTE LTD

2 Corporation Road, #06-01 Corporation Place,Singapore 618494

Tel: (65) 6622 5141 • Fax: (65) 6622 5100Editor: Victor Lim – [email protected]

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Contact: [email protected]

Copyright© 2014 Rockwell Automation Inc. All rights reserved. The contents of this publication may not be reproduced in whole or part without the consent of the copyright owner. Allen-

Bradley, CompactLogix, Connected Components Workbench, ControlFLASH, ControlLogix, E300, Encompass, FactoryTalk, Guardmaster, Integrated Architecture, Kinetix, Micro800, MP-Series,

PanelView, PlantPAx, PowerFlex, Rockwell Automation, Rockwell Software, RSLinx, RSLogic, RSNetWorx, RSTestStand, RSView, Stratix 2000, Stratix 5100, Stratix 5700, Stratix 5900,

Stratix 8000, Stratix 8300, Studio 5000, Total Cost To Design, Develop and Deliver and Vantage Point are trademarks or registered trademarks of Rockwell Automation, Inc.

Catalyst and Cisco are trademarks of Cisco Systems, Inc.

EtherNet/IP is a trademark of the ODVA.

Ethics Quotient, Ethisphere and World’s Most Ethical Companies are trademarks of the Ethisphere Institute.

Panduit is a trademark of the Panduit Corporation.

Excel, Microsoft and Windows are trademarks of the Microsoft Corporation.

Trademarks not belonging to Rockwell Automation are property of their respective companies.2 January 2015 AUTOMATION TODAY ASIA PACIFIC

Tom O’Reilly, President | Rockwell Automation, Asia Pacific Region

Making the Move to Smart Connected Enterprises

The Connected Enterprise – information-driven business systems that spark enterprise and value chain collaboration and decisions – has been a Rockwell Automation priority for

decades. As its supporting elements evolve, such as the Internet of Things technologies, the Connected Enterprise’s growth and resulting ROI are accelerating.

Moving from simple linked operations to smart connected enterprises is a process – one that involves the connection of operations technology (OT) to information technology (IT). This connection enables unprecedented collaboration across the enterprise, linking processes and facilities to suppliers and customers in new ways. It enables manufacturers, industrial operators and original equipment manufacturers (OEMs) to take advantage of real-time decision-making that drives profitability.

In striving to help our customers achieve the value of the Connected Enterprise, Rockwell Automation has pioneered a five-stage process used within and among its own global manufacturing sites, supply chains and customers. Called the Connected Enterprise Maturity Model, it incorporates measures and best practices to ensure effective change in OT, IT and across the organization. It also ensures our customers are securing their data and infrastructure from internal and external threats. In the process of developing this Model, Rockwell Automation has also collaborated with leading IT companies.

Stage 1 – Assessment: evaluates all facets of an organization’s existing OT/IT network including the information and physical infrastructure; controls and devices that feed and receive data; and security policies. Stage 2 – Secure and Upgraded Network and Controls: focuses on building an OT/IT backbone to deliver secure, adaptable connectivity from plant-floor operations to enterprise business systems. Stage 3 – Defined and Organized Working Data Capital (WDC): defines and organizes all of the company’s available data for improving business processes. Stage 4 – Analytics: deploys analytics based on the WDC that will deliver the greatest operational return and drive continuous improvement. Stage 5 – Collaboration: creates an environment that anticipates activities throughout the enterprise and helps the right people make the right decision at the right time.

Every manufacturer will enter and progress through the stages of the Connected Enterprise Maturity Model at a pace determined by its own needs, infrastructure, readiness and resources. Rockwell Automation has worked with organizations at the beginning of their OT/IT intelligence journeys as well as with companies already leveraging their WDC and collaborating with suppliers.

In this issue of Automation Today Asia Pacific, Rockwell Automation shares its insights on the Connected Enterprise. The cover article, The Connected Industrial Enterprise: Optimized to Create Value, describes the key issues related to the Connected Enterprise. Networks vs. Protocols: What is the Digital Difference? explores the role of Ethernet/IP™ in industry. Protect Machines with a Defense-in-Depth Strategy explains the importance of developing a security framework based on a multi-layer defense-in-depth strategy.

We encourage you to read this issue with an open mind to learn how your company can make the move to the Smart Connected Enterprise – and discover how Rockwell Automation can help your company connect people, processes and technologies to reduce costs and improve capabilities.

Features3 News & Events Rockwell Automation developments

from around the world.

4 Country News News and events from around

Australia & New Zealand.

6 Cover Story – The Connected Industrial Enterprise: Optimised to Create Value

Security is a key element in enabling manufacturers to leverage the Internet of Things (IoT) to help connect people, processes and technology – and achieve operational excellence.

10 Networks vs. Protocols: What Is the Digital Difference?

EtherNet/IP uses the tools and technologies of unmodified Ethernet, which has steadily evolved to provide high performance and network intelligence.

12 Protect Machines with a Defence-in-Depth Strategy

The defence-in-depth concept identifies and analyses potential internal and external security threats to production equipment.

14 Application Story Rockwell Software enables water plant

to improve performance efficiency and meet regulatory compliance.

16 Application Story Pohokura production station sets

the standard for remote operation & sustainability.

18 OEM Innovations Rockwell Automation helps OEMs

customise their machines.

21 Product Focus Recent additions to the Rockwell Automation

product portfolio.

Tom O’Reilly

Real-time information brings the ability to sense and manipulate plant processes on the fly.

AUTOMATION TODAY ASIA PACIFIC January 2015 3

Dalian Software R&D Campus Celebrates 20th Anniversary

Rockwell Automation recently celebrated the 20th anniversary of its software research and development campus in Dalian, China.

Over the past two decades, it has evolved from a two-engineer operation to the company’s largest software R&D center outside the United States.

The campus focuses on new product development and innovation. It supports the company’s strategy around The Connected Enterprise, bringing smart, safe and sustainable manufacturing to life by prioritising research on enhancing the integration of control and information systems.

Rockwell Automation Chairman and CEO Keith Nosbusch says, “I continue to be impressed by how our Dalian campus has evolved into a truly great asset for our global R&D capabilities, providing support not only for our global customers but also serving local customers in China. China is a strategic and important market for our continued global success, and it is our long-term strategy to strengthen our innovation capabilities in China and cultivate more local talent to better serve the China market.”

The convergence of control and information technologies – coupled with new technologies such as mobility, cloud and big data analytics – is reshaping the manufacturing landscape. The Dalian campus will play a significant role in supporting the Rockwell Automation vision for The Connected Enterprise.

NEWS & EVENTSCybersecurity Framework Reduces Risks to Critical Infrastructure and Manufacturing

Rockwell Automation has endorsed the Cybersecurity Framework of the National Institute of Standards and Technology. The voluntary framework reflects input from Rockwell Automation and a diverse group of industry stakeholders who share a common objective to increase the resiliency of and reduce cybersecurity risks to critical infrastructure and manufacturing.

Cisco Internet of Everything Partner

Rockwell Automation recently announced that it has been awarded the Cisco® Internet of Everything Partner of the Year at the Cisco Australia and New Zealand Partner Insight Awards in Melbourne.

The award celebrates innovation, leadership and excellence within the business community. Award criteria include innovative and architecture-led approach to success, business differentiation and strategic outcomes, and deep customer understanding.

BRIEFS

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Dalian Campus Product Transition

• FactoryTalk® ViewPoint

• Connected Components• Workbench™ software

• RSLogix™ 5000 Compare Tool• FactoryTalk• FactoryTalk AssetCentre• RSLogix Architect• RSMACC

• ControlFLASH™ software• FactoryTalk Live Data• RSLinx® Enterprise

• Alarms and Events• FactoryTalk Activation Manager• FactoryTalk Gateway• FactoryTalk Transaction Manager

• FactoryTalk Historian SE• RSTestStand™ Enterprise

• FactoryTalk Historian Classic• FactoryTalk Scheduler• FactoryTalk Metrics• RSLogix 5000

• FactoryTalk View• RSNetWorx™

• RSLinx Classic• RSLogix 500

• RSView®32

• Entrx

• EMONITOR®

Ethisphere Institute Honors Rockwell Automation

For the sixth time, the Ethisphere® Institute has named Rockwell Automation as one of the “World’s Most Ethical Companies®,” a recognition that honors organisations that continue to raise the bar on ethical leadership and corporate behavior.

The Ethisphere Institute is an independent centre of research promoting best practices in corporate ethics and governance. World’s Most Ethical Companies honorees understand the correlation between ethics, reputation and business success.

The World’s Most Ethical Companies assessment is based upon the Ethisphere Institute Ethics Quotient™ framework. Scores are generated in five key categories: ethics and compliance program (25%); reputation, leadership and innovation (20%); governance (10%); corporate citizenship and responsibility (25%); and culture of ethics (20%).

Rockwell Automation also announced that its latest Corporate Responsibility Report is now available online and in print. The report highlights updates on the company’s environmental performance, employee safety and culture, and community relations efforts. To learn more, visit: http://www.rockwellautomation.com/ rockwellautomation/about-us/sustainability-ethics/integrity-compliance- overview.page?

NEWSCOUNTRY

4 January 2015 AUTOMATION TODAY ASIA PACIFIC

FIRST Robotics brings Regional event ‘down under’ in 2015

Automation University is coming to a town near you

Robot mania is set to hit Sydney as robots race to compete in the FIRST (For Inspiration and Recognition of Science and Technology) Robotics Competition (FRC). FIRST, world’s leading robotics program will host the first Australia’s regional competition at the Sydney Olympic Park Sports Centre on March 11-14, 2015. Teams from Australia and around the world will take part in the FIRST Robotic Challenge (FRC) Regional event. “This will be the first time that we’re holding a regional competition in Australia so it’s great to see that we already have teams registering from not only around Australia but also other countries including, Hawaii, Brazil, Taiwan, China and Singapore,” said Luan Heimlich, Regional Director for FIRST Australia.

In this event, teams will have about six weeks to brainstorm, design, prototype, build, program and learn to drive a robot before putting them to the ultimate test in this large scale robotics competition. The robots themselves are up to two metres tall and weigh as much as 50 kilograms. In addition to competing in the robotics game, participants are also in the running for three prestigious awards; the Chairman’s Award, Engineering Inspiration Award and the Rookie All-star Award. The winning alliance and these award winners will be invited to compete in the FIRST World Championship event, to be held in St. Louis, Missouri, USA. FIRST’s mission is to inspire young people to be science and technology leaders, by engaging them in exciting

mentor-based programs that build science, engineering and technology skills, that inspire innovation, and that foster well-rounded life capabilities including self-confidence, communication, and leadership. As one of the key global sponsors for FIRST, Rockwell Automation is committed to encouraging students to study a science, technology, engineering or maths (STEM) field at university. The company was the recipient of the Founder’s Award at the 2013 World Championships for their continued sponsorship of FIRST. “Rockwell Automation is a great supporter of FIRST. The program has really taken off in Australia, we started small but we now have 30 teams. I think that once people talk to participants in the program, they really see and understand the power of the program and then look to becoming involved,” said Heimlich. The theme for next year’s Regional event will be announced closer to the date but will no doubt combine the excitement of sport with science and technology to create a unique varsity Sport for the Mind™. FRC helps young people, aged 14-18, discover the rewarding and engaging world of innovation and engineering. To see FIRST in action visit Australia’s first Regional Event at the Sydney Olympic Park Sports Centre from 11-14 March, 2015.

Rockwell Automation is pleased to announce that Automation University will be touring regional centres around Australia and New Zealand throughout 2015. Following the success of previous years, this one-day event will highlight leading-edge automation solutions. According to Matthew Treeby, commercial marketing manager at Rockwell Automation, “Automation University will provide a unique, in depth experience with technology. We have designed a program that is full

of insight, vision, ideas and practical solutions to help participants stay ahead of their competition.” “Technology is moving at such a fast pace that organisations can’t afford to be left behind, but may also be short of time to keep up with the latest advances. To help organisations meet their business and plant requirements, Automation University will provide the platform to bring together people and products, as well as technologies and solutions,” he explained. Attendees will have the valuable

opportunity to learn by experience through interactive demonstrations, hands on labs and presentations that show real-life industry environments and scenarios. Rockwell Automation specialists and industry leaders from our PartnerNetwork™ will lead each session. Each location will offer two or more streams, focussed on topical themes to ensure attendees can design their personal workshop program and follow technology sessions of their choice. Rockwell Automation is committed


The Internet of Things (IoT) has emerged as one of the most transformative and growing technology trends today. As the industrial plant floor and corporate enterprise become more connected, the demand for skilled professionals who understand the exchange between information technology (IT) and operations technology (OT) is increasing. Establishing a connected industrial enterprise may appear to be an overwhelming challenge but it is one that manufacturers must address to remain competitive in the current marketplace. In response, Rockwell Automation together with Strategic Alliance partner Cisco, has launched a new training course, Managing Industrial Networks with Cisco® Networking

Technologies (IMINS). This is a hands-on lab-based course, which helps students with the foundational skills needed for the management and administration of networked industrial control systems. According to Cuong Vo, business manager, Customer Support & Maintenance at Rockwell Automation, “Automation engineers are increasingly required to manage networked industrial products and solutions so this course is designed for IT and OT professionals and control engineers who are involved with the implementation, operation and support of networked industrial products and solutions,” “This course aims to enable participants to achieve competency and skills to install, maintain and troubleshoot industrial network

systems while helping to ensure network availability, reliability and Internet security throughout their companies,” he said. Industrial IoT technologies

can help customers lay a foundation for a highly secure, connected enterprise using standard unmodified Ethernet to connect people, processes, data and things. This ultimately drives greater productivity and sustainable competitive differentiation. The five-day course focuses on networking technologies that are needed in today’s connected plants and enterprises. Participants will get hands-on experience working with the Rockwell Automation suite of products to help converge technologies and bring the value of the connected enterprise to life. It also provides a foundation for the Cisco Industrial Networking Specialist Certification exam. Rockwell Automation and Cisco have been working together to bridge the gap between enterprise IT and plant floor operations technology professionals through network and security products, Converged Plantwide Ethernet (CPwE) reference architectures, services and solutions. The IMINS training course will be conducted as part of the Rockwell Automation ConnectED 2015 and Cisco Live 2015 in Melbourne from 16-20 March and subsequently in other locations around Australia.

Rockwell Automation and Cisco deliver networking technologies training course throughout 2015

AUSTRALIA & NEW ZEALAND

to helping customers succeed and gain a competitive advantage through hosting events such as Automation University. From stand-alone, industrial components to enterprise-wide integrated systems Rockwell Automation solutions have proven themselves across a wide range of industries and environments. Whether you are an engineer, end user, machine builder or consultant, visit Automation University for up to date, views, trends and technologies of integrated information and automation

solutions.The Automation University events are completely free of charge – but places are always in great demand, so anyone wishing to attend is encouraged to register early. Don’t miss this unique opportunity to see, touch and experience the complete

offering from Rockwell Automation.For more information visit: www.rockwellautomation.com.au


E stablishing a Connected Enterprise is more complex than simply connecting disparate systems.

It means having access to real-time and historical data, wherever it’s being produced, and all of the business and transactional data that will affect different plants and their operations.

It involves seamlessly and securely connecting all control and information levels of an organisation. As the historic disconnect between enterprise and plant-floor networks is bridged, industrial firms need to better understand potential security risks. Whether it’s your network, assets or intellectual property, operations need to be secure from potential threats – whether they’re accidental or intentional, internal or external.

“When we speak to our customers about moving a Connected Enterprise forward, it’s not unusual for them to raise two concerns: cost and security,” says John Nesi, Rockwell Automation vice president of global market development. “As we discuss this, we have to realise that the vision of the Connected Enterprise includes value creation.”

“By letting people know what’s really happening in the enterprise, the Connected Enterprise creates real customer value by turning data into information into knowledge and, ultimately, into wisdom,” says Keith Nosbusch, chairman and CEO, Rockwell Automation. This requires a common, secure Ethernet infrastructure to integrate control and information.

“That value opportunity comes directly from the technology opportunity. Having the technology and the knowledge to distill all of the business and transactional data into information that provides true innovative value is the next frontier,” Nesi says.

Technology Transformation“We’re in the middle of a technology

transition that has a big impact on business,” explains Rob Soderbery, senior vice president and general manager of the Enterprise Networking Group at Cisco®, a Rockwell Automation® Strategic Alliance Partner. According to Soderbery, three macro trends are influencing that transition:1. The economics of the growth of

emerging vs. developed countries.2. Energy consumption and what

the demands and sources will be in the future.

3. Social demographics of hyper growth in emerging markets, and declining workforce and aging population in developed countries.

Productivity, he adds, will be at the heart of solutions dealing with these issues. “The next wave of productivity will come out of the Internet of Things, or IoT.” The IoT includes the seemingly infinite number of devices and their interconnectedness via Internet Protocol (IP). By 2020, it is estimated that there will be 50 billion connected things connected to the Internet.

In fact, Cisco says there’s $14.4 trillion in increased value to be realized in the private sector over the

The Connected Industrial Enterprise:

Security is a key element in enabling manufacturers to leverage the Internet of Things (IoT) to help connect people, processes and technology – and achieve operational excellence.

V isit these resources to learn more about the Connected Enterprise and how it can make

a real difference in your operations.

• Video: Rockwell Automation President and CEO Keith Nosbusch’s Keynote Presentation “The Connected Industrial Enterprise” from the 2014 Internet of Things World Forum

• Video: RSTechED 2014 Presentation about the Connected Enterprise and Industrial Security

• Free White Paper: The Connected Industrial Enterprise [PDF]: Why Unlocking Data to Enable a Connected Enterprise is Vital to the Future of Manufacturing

• Websites: Learn more about the Connected Enterprise at www.rockwellautomation.com/ rockwellautomation/innovation/connected-enterprise/overview.page?. Also visit www.industrial-ip.org/community/blog.

LEARN MORE ABOUT THE CONNECTED ENTERPRISE

Optimised to Create Value


next 10 years in the IoT. “That value,” notes Soderbery, “will come from benefits in innovation expansion, enhanced customer experiences, asset utilisation, employee productivity, and supply chain and logistics improvements.

He adds that about $3.7 trillion of that $14.4 trillion will come in the manufacturing sector.

“But the big impact, the stunning opportunity here, is in industry,” he says. “When you can connect things, processes and data in the cloud, you can create new real-world applications in logistics, in segments that are upstream in the supply chain.” The cloud offers remote access to devices and information, massive storage and the computing power needed for complex analytics.

In addition to remote access, people want the ability to access information on the go, making security a high priority. Big data and analytics empower collaboration, and “manufacturing generates more big data than any other sector,” says Nosbusch.

Security at the ForefrontClearly, many challenges exist, from

converging and merging disparate networks, to harvesting distributed intelligence by pushing analytics out to the data sources, to ease of use. However, the one that trumps them all, Soderbery says, is security.

So why is IoT security different? One of the reasons is the “attack surface.”

Soderbery explains, “The attack surface of a factory is large and complex. Remediation also is different. What do you do if you’re under attack in the process industry? Shutting down is not a practical or easy response.”

He presents a few ideas for IoT security. “Access control is more than

a firewall. You have to be aware of the content on the network through tools like deep-packet-inspection engines. A second thing is the context. What’s the device, what data does it produce, is it where it says it is? You can draw some conclusions through the combination of content and context.” This contributes to improved threat awareness and an understanding of the threat landscape.

Mike Assante is advisor and director for the National Board of Information Security Examiners. He is the SANS Institute project lead for industrial control system (ICS) and supervisory control and data acquisition (SCADA) security. He says that the desire for analytics isn’t just restricted to the manufacturer and its supply chain.

“Companies such as the equipment and machine builders themselves want access to the equipment they sold you, and want to better understand the operating envelopes of those machines to help optimise those machines and enable them to perform more safely,” he explains.

Assante notes that threats to industry are becoming more targeted and structured. He reports that up to 94% of those targeted attacks aren’t discovered by the victim until they learn about it through a third party, or learn that some of their information was found on someone else’s server.

“In all these reported cases,” says Assante, “the companies were up-to-date with their antivirus solutions and used industry security practices, but still were compromised. It tells us that our conventional security approach isn’t working for that type of threat.”

It’s time to adapt, he proposes. Assante explains that we have to secure our people first and recommends that automation engineers work with

cyber-security personnel and vice-versa to cross-educate their strengths and needs. This can lead to new approaches to better security.

Bringing the Cloud Down to Earth

Some wonder how the cloud and the IoT will affect their daily work lives in the industrial plant.

“To us, big data means all the information running on plant floors, so our mission is to help our customers find the best ways to make sense of

Rockwell Automation and its Alliance Partners are committed to helping manufacturers

improve business performance by bridging the technical and cultural gaps between plant-floor and higher-level information systems. For example, Rockwell Automation works with Cisco®, a worldwide leader in Internet networking, on various initiatives, including joint products and solutions.

Cisco and Rockwell Automation developed the Stratix 5700™, Stratix 8000™ Layer 2 and the Stratix 8300™ Layer 3 managed industrial switch lines, creating a networking environment for both IT and controls professionals. Using the current Cisco Catalyst® switch architecture and feature set, along with configuration tools, the product line helps to provide secure integration with the enterprise network. Visit www.rockwellautomation.com/partners/ cisco.html for more information.

THE POWER IN STRATEGIC ALLIANCES


it all,” says Keith McPherson, market development director, Rockwell Software®. “We help users connect to their information, organise it, put it into the right context, set up dashboards and distribute it to the right individuals who can make better and more profitable decisions.”

He continues, “Over a decade ago, we made a decision to base the Integrated Architecture® system on standard, unmodified Ethernet. That’s what’s making it easier for us to implement the virtual computing and cloud-based services so many users are asking for now.”

Rockwell Software now offers its FactoryTalk® VantagePoint® Mobile App in the Windows® Store, which is based on the FactoryTalk VantagePoint enterprise manufacturing intelligence (EMI) software, Version 5.0. Featuring Windows 8-style on-screen tiles, this new app can provide any key performance indicators (KPIs) users need right at their fingertips, McPherson says.

To help support these apps, big data and cloud-based projects with some heavy-duty virtualisation hardware, Rockwell Automation offers its Industrial Data Center, a pre-engineered, scalable infrastruc ture that lets users run multiple operating systems and applications on virtualised servers. It includes an enclosure and temperature controls by Strategic Alliance Partner Panduit®, and Unified Computing System

(UCS Servers and Catalyst switches) from Strategic Alliance Partner Cisco. It has the ability to run a virtualised PlantPAx® system and a variety of FactoryTalk and other third-party software packages on a user’s private cloud.

More Demand, More Attention Needed

As the global population accelerates toward 8 billion, millions of people are exiting poverty, and an expanding middle class will demand more food, housing and transportation – goods that will have to be manufactured and distributed. This will increase demands on manufacturers and on infrastructure, water supply and raw materials. Increasing demand for scarce resources will drive inefficiencies out of manufacturing, leading to a need to spend an estimated $1 trillion on resource productivity, Nosbusch says.

“We believe that we are at an inflection point drawn by the integration of the Internet of Things and the Connected Enterprise,” he says.

That makes attention to security even more vital as the Connected Enterprise and technology that supports it enables the collaboration among people, plant-floor systems and the enterprise for seamless, secure, productive operations. (See the article in this issue entitled Protect Machines with a Defence-in-Depth Strategy.) AT

STORYFEATURE

A s organisations seek greater visibility into their operations, OEMs must help establish

a smooth flow of information from the machine level to the enterprise. Below are the steps OEMs can take to securely integrate machines and equipment into a plant network, protect intellectual property at the machine level and provide secure remote access for end customers.

1. Control who has network access using tools, such as access control lists and port-blocking features/devices.

2. Employ firewalls and intrusion detection/prevention.

3. Use anti-virus protection and whitelisting.

4. Establish a system-patching policy to keep software up to date.

5. Develop procedures for employee-security practices, such as managing and protecting passwords, managing removable media and use of personal devices.

6. Physically block changes to your controller by putting it in Run Mode.

7. Control who is allowed to do what from where in the application with FactoryTalk Security architecture.

8. Monitor what is going on in your system with Controller Change Detection and FactoryTalk AssetCentre system.

9. Protect your intellectual property with Logix Source Protection.

10. Ensure all Ethernet devices are connected using standard Internet Protocol.

OEMS IN THE IoT PLANT

www.prosoft-technology.com

[email protected]

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Networks vs. Protocols: What Is the Digital Difference? EtherNet/IP uses the tools and technologies of unmodified Ethernet, which has steadily evolved to provide high performance and network intelligence.

WATCHTECHNOLOGY

L ike many words in the English language, “network” and “protocol” have different meanings, depending

on the context. For example, your interpersonal network is far different from a railway network. In the context of digital communications, the Merriam-Webster dictionary defines network as “a system of computers, peripherals, terminals, and databases connected by communications lines.”

The world’s most common computing network is Ethernet, uniformly defined under IEEE 802.3. More than 85 percent of the world’s LAN-connected PCs and workstations

rely on standard Ethernet, which allows seamless networking of electronic devices, regardless of their operating system.

Protocols, in the context of digital communications, require a slightly longer description in Merriam-Webster: “For computers to exchange information, there must be a preexisting agreement as to how the information will be structured and how each side will send and receive it. Without a protocol, a transmitting computer, for example, could be sending its data in 8-bit packets while the receiving computer might expect the data in 16-bit packets.” Protocols are defined by international or industry organisations, such as the IEEE and the Internet Engineering Task Force (IETF).

Critically, the definition points out that the most essential and powerful of these technical standards is

Internet Protocol (IP), explains Paul Brooks, business development manager, Rockwell Automation. The vast majority of digital developers worldwide use IP to continuously advance information handling and task management.

IP is the primary protocol that supports today’s global, multimedia information and communications system. Relying on an open-architecture networking environment – primarily standard Ethernet – IP has enabled the invention and interoperability of a vast array of electronic communication devices.

IP: The Powerhouse Protocol IP provides the common electronic

language that allows different devices not only to coexist on a network but also to interoperate. IP organises data into a common digital structure, enabling everything from computer hardware and software to cell phones and smartphones to interact and connect to the Internet.

While IP is commonly referenced as part of the TCP/IP protocol suite (TCP standing for Transmission Control Protocol), IP is the powerhouse of the pair. It implements key network functions, including addressing, packet handling and routing. IP also is the foundation on which other TCP/IP protocols, as well as numerous applications, are built.

IP functions at the Network Layer (layer three) in the Open Systems Interconnection (OSI) reference model. That means it runs on top

of the physical and data-link layers defined by IEEE 802.3 – otherwise known as Ethernet.

These two standards are not only formally recognised, their combined use is nearly ubiquitous – except in a portion of industrial automation. Traditionally, many manufacturers have relied on dedicated, purpose-built proprietary networks for the plant floor automation, with the rest of the enterprise communicating via standard, unmodified Ethernet.

This has contributed to a digital divide between plant- and site-wide operations and the overall IT infrastructure, often creating islands of automation in the manufacturing realm, says Brooks. Without standard, unmodified Ethernet on the plant floor, many industrial automation companies can’t easily take advantage of higher-level protocols and the immense functionality they support including FTP, to send files; SMTP, to send emails; HTTP, to browse the web; and VoIP, to transmit calls.

Equally important, the majority of network security innovations are designed to work in conjunction with IP. Cisco® estimates that global cybersecurity investment will exceed $86 billion in 2016, and the UK’s National Audit Office believes that 80 percent of enterprise-level attacks could have been prevented through deployment of commercially available technology.

Some protocols have been built specifically for industrial applications, such as the Common Industrial Protocol (CIP). It encompasses a comprehensive suite of messages and services for the collection of industrial automation applications – control, safety, synchronisation, motion, process, configuration and information. It is important to

IP is the primary protocol that supports today’s global, multimedia information and communications system.


remember that Ethernet is just a transport mechanism, and it is the upper-layer protocols riding on top of it that enable true interoperable communication. Thus, CIP provides a unified communication architecture throughout the plant- or site-wide network infrastructure.

Standard Ethernet vs. “Ethernet-Based”

Why haven’t all automation companies adopted standard Ethernet-enabled IP? The reasons vary, though most are rooted in the fact that the plant floor is a much more rugged and demanding environment than the average office, and its networking demands are different.

Instead of accessing files and printers, Brooks explains that plant floor controllers must access data embedded in controllers and drive systems, operator workstations and I/O devices. Plus, plant floor data communications needs are real-time, or very close to real time.

Also, in the past, standard Ethernet equipment and cabling lacked the durable, ruggedised “industrial” strength necessary to stand up to tough conditions often found on plant floors. Those reasons for resistance have been well overcome by advances like EtherNet/IP™, which combines unmodified Ethernet, IP and CIP. Furthermore, hardened hardware, ruggedised cabling and other equipment have also helped to dispel some Ethernet doubts.

Still, some manufacturers have remained tied to the proprietary plant networks of the past, or they’ve been convinced by entrenched vendors that “Ethernet-based” technology is equal to standard, unmodified Ethernet.

It is not. Derivatives of IEEE 802.3 – and

more importantly, the TCP/IP protocol suite – often don’t come with the same capabilities. So, for example, manufacturers that do not use standard Ethernet and TCP/IP technologies often can’t seamlessly connect the plant networks to the rest of the IT infrastructure without using

special hardware or protocol gateway devices. Such add-on technology can add cost and complexity to network owners. These additional items also add one more point of system configuration or failure. Furthermore, they may be tied to a limited vendor supplier set or technicians.

What do we mean by seamless? We mean the ability to do real-time routing outside of a layer 2 LAN or layer 3 subnet. Or, said another way, no data mapping!

EtherNet/IP = IEEE.802.3 + IP + CIP

Manufacturers that rely on EtherNet /IP as their industrial network can seamlessly share plant-wide information. That’s because EtherNet /IP is truly an IEEE 802.3 standard. And, it adheres to the wireless standard, 802.11.

EtherNet/IP uses the tools and technologies of unmodified Ethernet, which has steadily evolved to provide high performance and network intelligence. Speeds have risen from 10 Mbps to 100 Mbps to one gig and beyond.

Meanwhile, engineering enhance-ments have made EtherNet/IP a multi-discipline platform, converging operations with plant-floor control,

motion, process and safety applica-tions. Thus, EtherNet/IP enables organisations to save money by moving away from expensive, closed, plant floor dedicated networks.

EtherNet/IP provides users with the tools to deploy standard Ethernet technology for industrial applications. The result: performance and data anytime, anywhere.

In addition, EtherNet/IP’s familiar Internet technology means users can more quickly and easily learn how to operate systems connected to the network. Plus, without separate networks to worry about, engineers can more easily and quickly integrate machines into the plant, significantly lowering start-up costs.

Today, a broad range of EtherNet/IP product lines are offered by more than 300 vendors worldwide. EtherNet/IP also works transparently with all standard, off-the-shelf Ethernet devices found in today’s marketplace and can be easily supported on standard PCs and their derivatives.

EtherNet/IP allows users to put the full power of the Internet Protocol to work for industry, now and far into the future. AT

This graphic shows adherence to IEEE 802.3 and the IETF TCP/IP protocol suite while also illustrating that real-time communication is guaranteed.


Protect Machines with a Defence-in-Depth StrategyThe defence-in-depth concept employs multiple layers of security controls to protect the integrity of components or systems.

The increasing adoption of EtherNet/IP™ in production is being accompanied by increasing

convergence between operations and business systems. This gives operations professionals broader and deeper access to production data and the elements that support them.

Business and production managers can quickly access the relevant levels of information, enabling them to make decisions based on real-time data. However, the convergence of the office and production systems also requires security strategies – particularly for the production network, as it is no longer an isolated network within the company.

Rockwell Automation, working with its collaborators, has adopted a security framework that is common between the manufacturing and enterprise network. The concept, based on a “defence-in-depth” strategy to protect production assets, warrants a closer look.

Examining the StrategyThe defence-in-depth concept uses

multiple security countermeasures to protect the integrity of components or systems. It is based on the idea that any one point of protection may, and probably will, be defeated. This approach requires multiple “layers” of defence – physical, network, computer, application and device – to help ensure a weakness or flaw in one layer can be protected by strength, capabilities or new variables introduced through other security layers.

For example, physical security mechanisms – such as guards and gates – limit physical access of areas, control panels, devices, cabling, the control rooms and other locations to authorised personnel. Network security applies to the network infrastructure,

such as firewalls with intrusion detection and intrusion prevention systems (IDS/IPS), and integrated protection of networking equipment, such as switches and routers.

At the computer layer, patch management and antivirus software – as well as removal of unused applications, protocols and services – help to “harden” the hardware from attacks. Application security relies on authentication, authorisation and audit (AAA) software to help prevent unauthorised access or changes. At the device layer, change management, communication encryption and restrictive access help to harden factory-floor devices.

A systems-oriented approach to industrial security can help manufacturers proactively assess and address risks in their control systems. Rockwell Automation teams with industry leaders to help manufacturers and machine builders incorporate these layers of security into machinery.

Elements of Automation Security

Control systems, networks and software, as key elements of an overall security strategy, can help defend against security threats and risks in manufacturing.

For example, programmable automation controllers (PACs), human-machine interfaces (HMIs), drives, and other intelligent connected devices should be developed using a design-for-security philosophy that helps harden products against common attacks. The philosophy includes features to facilitate physical and logical access control and intellectual property (IP) preservation.

The Rockwell Automation® CompactLogix™ PACs, for instance,

are able to participate in FactoryTalk® Security services, which help verify the identity of users attempting to access the automation system and the types of actions they are authorised to take. Rockwell Software® Studio 5000® v20 (and later) features change detection and logging capabilities to protect IP and detect modifications made to the system.

Network solutions must meet the unique needs of industrial automation and IT. The infrastructure will most likely include devices that provide secure routing and firewall capabilities, virtual private networks (VPNs), access control lists (ACLs) and IPSs. Switches must also support ACLs as well as device authentication, unauthorised device identification and encrypted administrative traffic.

The Stratix 5900™ Services Router from Rockwell Automation combines several security functions into a single appliance to protect the industrial automation and control systems’ network at the perimeter and at the cell/zone level. The Stratix managed switches use a leading-edge switch architecture and feature set, along with powerful configuration tools, helping to provide secure integration with the enterprise network using tools familiar to IT professionals. At the same time, they allow easy setup and diagnostics from within the Rockwell Automation Integrated Architecture® using tools familiar to manufacturing professionals.

On the software side, applications used in conjunction with control systems should verify the identity of users and help secure access to the control system. For instance, FactoryTalk Security from Rockwell Automation provides user access controls and role-based security to controllers, HMIs and software

WATCHTECHNOLOGY


while FactoryTalk® AssetCentre tracks users’ actions, manages asset-configuration files and provides backup and recovery of operating asset configurations.

Protecting the Control System

There are two ways to provide remote access to a control system, direct and indirect. Direct access allows an external user to establish a secure connection directly into an industrial automation control system (IACS), production line or machine. Remote users can access the system once a VPN tunnel has been set up to initiate communication from the software on the computer being used for access to the IACS.

Indirect access to an IACS provides communication via an intermediate remote access server (RAS) located in the operator’s “demilitarised zone (DMZ),” a buffer area providing a barrier between the manufacturing and enterprise zones while allowing users to securely share data and services. Once the VPN connection has been established, the external client uses either a thin client software application or a web browser to set up the connection to the RAS.

Indirect access to a control system is the preferred access method in a production environment, as this approach sets up a temporary “trusted image” used to access the control system. Trusted assets can talk to the control system, but threats are not able to easily pass back and forth.

Challenges for Machine Builders

Machine builders always strive to reduce the cost of their product, provide added value to their customers and differentiate themselves from their competitors. However, they also need to protect their investments and expertise – the basis of their added value and differentiation – from unauthorised access by third parties and from unintentional damage by their customers’ staff.

Implementing a complete defence-in-depth strategy could pose

challenges for machine builders. An IACS is usually managed by the company’s production division while enterprise access – via solutions such as VPNs – is handled by the IT organisation. Therefore, it is essential that the machine builder collaborate with IT and production when implementing a security structure that takes the company’s security policies into consideration.

In addition, system access given to untrusted devices, such as a computer owned by an external business partner, exposes a production system to viruses and malware. For example, access to the control systems could be based on a dial-up modem connection that circumvents the manufacturer’s firewall. This external access bypasses the customer’s security perimeter and provides “back-door” access via the production system.

Use of back-door access is not preferred, as the system is not typically monitored and requires more investment into security devices to be placed at each access point. In many cases, the machine builders are smaller companies with with much fewer security measures in place; their solutions can serve as an easier route into a system than attacking larger customers’ systems

directly. In this scenario, machine builders can potentially expose their customers, and their own businesses, to significant risk.

Machine builders have a responsibility to provide and/or comply with customer security policies. They will want to employ product security features to enhance IP protection and data confidentiality and use system capabilities that restrict access and define roles and responsibilities.

Rockwell Automation delivers a combination of industrial control system design and best practices, contemporary technologies and professional services that help manufacturers and machine builders address risk and improve performance. Successful collaboration with strategic partners results in unique expertise and insights that facilitate the design and management of a more secure connected enterprise.

Companies that establish a secure environment will make the most of the promise and benefits of the Connected Enterprise – including cloud, virtualisation, mobile devices and other emerging technologies while protecting mission-critical automation functions and assets. AT


The Waikato River – the longest river in New Zealand – supplies all of Hamilton city’s water sup-

ply. Water is treated, distributed and managed by the Hamilton City Council to ensure that when water reaches con-sumers, it is free from harmful organisms and meets water supply standards.

Hamilton’s reticulated (piped) water supply system consists of one water treatment plant that provides potable water to eight different reservoirs located around the city through over 1,000 km of piping. The reticulated network delivers the water straight to the taps of consumers. Every second of each day, Hamilton City Council produces an average of 2,385 glasses of high quality drinking water to over 51,000 homes and industrial premises.

The council is also responsible for the operation of the Pukete Wastewater Treatment Plant, which services a region that has grown rapidly in recent decades to have a population in excess of 150,000. Like the city, the Pukete WWTP is continually developing, in its case to improve operational performance and

maintain compliance with a changing government regulatory environment.

Leveraging the FactoryTalk® Integrated Production and Performance Suite from Rockwell Automation, Hamilton City Council implemented

an upgrade to their supervisory control and data acquisition (SCADA) system at the plant, enhancing the ability of key stakeholders to make informed decisions, improve performance efficiency and meet regulatory compliance.

Efficient ComplianceAfter the New Zealand Ministry of

Health issued revised drinking water standards in 2008, water treatment facilities have had to track, save and provide monthly reports on water production, intake and discharge levels. Crucially, the standards require that water treatment plants retain operating data for 10 years.

More than a decade ago, Rockwell Automation provided the Hamilton City Council with the software suite for its previous SCADA system. However, the RSView32 system had become outdated over time and inefficient for compliance with modern-day regulatory requirements set out by the New Zealand government.

With its previous SCADA system, the council had often recorded data

manually before transferring this information into Microsoft® Excel® spreadsheets for reporting. A faster, more accurate and automated reporting system was needed, one that could rapidly generate pre-determined

reports automatically for sharing with authorised groups.

“Our previous system was outdated, and we required an upgrade to help simplify the process of complying with current water regulations in New Zealand, “ says Gary Pitcaithly, automation and electrical manager at Hamilton City Council. “Not only that,” he continues, “but we identified the potential for improving operational efficiencies at the plant by implementing an integrated system that aims to increase productivity and reduce downtime.”

A key aim of the upgrade was to deliver a system with the ability to retain 10 years of data in a stable and reliable manner. At the same time, the system would need to provide operational efficiencies compared with the previous operating system while also maintaining a secure environment only accessible by authorised stakeholders.

To improve on this process, Hamilton City Council engaged Rockwell Automation to provide the latest versions of the FactoryTalk software suite as the integral element of an upgrade to its system.

According to Prasad Nory, industry manager – South Pacific at Rockwell Automation, “FactoryTalk Historian and FactoryTalk VantagePoint® are increasingly becoming standards in the water/wastewater industry, especially with the need for compliance to changing drinking water standards. Also, FactoryTalk Historian ME has been used by some councils in their pump stations to store data locally to take care of communication failures and meet compliance.

“By upgrading to the FactoryTalk suite,” he continues, “the key benefits identified by council included superior

Hamilton City Council Meets Compliance Demands with System UpgradeRockwell Software enables water plant to improve performance efficiency and meet regulatory compliance requirements.

STORYAPPLICATION

By upgrading to the FactoryTalk suite, the key benefits identified by council included superior reporting for compliance to government regulations, improved system reliability and stability, and reduced risk when contractors are onsite to undertake modifications or further expansions.


reporting for compliance to government regulations, improved system reliability and stability, and reduced risk when contractors are onsite to undertake modifications or further expansions.”

The FactoryTalk software suite delivers a real-time exchange of information throughout organisations, a critical element that allows for more informed business decisions, improved responsiveness, increased productivity, reduced costs and ease of compliance with regulations.

Implemented in-house by Pitcaithly, Hamilton City Council upgraded the WWTP’s system over six months to include the FactoryTalk View (SE), FactoryTalk Historian, FactoryTalk VantagePoint, FactoryTalk AssetCentre and FactoryTalk ViewPoint applications. The Rockwell Automation® Customer Support and Maintenance team provided support to the council during the upgrade, particularly for the migration from Historian Classic to FactoryTalk Historian.

The long-term storage and reporting capabilities required to comply with water standards are provided by FactoryTalk Historian and FactoryTalk VantagePoint. Data is stored in the Historian server for the required 10 year retention period and is easily accessed for analysis and reporting purposes.

FactoryTalk VantagePoint is used by the plant to schedule and produce automatically generated reports providing information on periodical water consumption, discharge, intake, water quality and storage levels. FactoryTalk AssetCentre provides improved contractor control, change management and storage capabilities.

Most importantly, the plant is now positioned to efficiently comply with water regulations in New Zealand, including the storage of data and records for 10 years.

Delivering Fresh Water and Improved Responsiveness

The benefits of the new Integrated Architecture® solution will help the plant supply fresh drinking water and a clean environment to residents of Hamilton for many years to come. According to Pitcaithly, historical and reporting data

is now available more quickly and accurately following implementation of the FactoryTalk suite.

“The upgrade has delivered greater ease of use of our system throughout the WWTP. The new Historian is superior in how it stores data and makes generating information for vital reports a much more efficient task to undertake,” explains Pitcaithly.

“The VantagePoint software,” he continues, “allows us to develop reports at will, whether it is for compliance to water standards or for other needs. These reports can then be published as web-based reports that are available for anyone authorised to view them.”

Another key result of the upgrade has been the flexibility it has added for personnel operating the system at the WWTP.

Pitcaithly says, “The FactoryTalk software suite has enabled our team to be more flexible with their time, as we are now able to edit or update reports as we go. We now simply store our data directly into Historian, and the data spreads directly from the programmable automation controller (PAC) to a human interface. This data is incorporated into spreadsheets for us to interrogate, whether it is on a daily, weekly or monthly basis, to tell us if we’ve had a breach in turbidity or if chlorine levels aren’t what they should be.”

The flexibility extends to the ability of system users to remotely access the software from tablet computers or smart phones. “The team has tablets and smart phones that can basically access FactoryTalk View anywhere in the world. If they are out of the office or on-call, the system can be easily accessed and key changes made,” concludes Pitcaithly.

With the FactoryTalk software suite delivering new found operational potential for the plant, the council is planning to continue to update and improve its system further in the coming years in order to utilise these capabilities. AT


Pohokura sets the standard for remote operation and sustainabilityLocated off the Northern Taranaki coast, the Pohokura field is New Zealand’s largest natural gas resource. To achieve zero normal operational presence (ZNOP), the Pohokura production station implemented a new integrated automation control system from Rockwell Automation.

Natural gas is a very valuable resource. It is an environmentally friendly, clean fuel when

compared to other fossil fuels. Natural gas is more efficient with 90 per cent of production reaching the point of consumption. The efficiency is constantly improving with technological advances in extraction, transportation and storage techniques. The transportation system for natural gas consists of a complex network of pipelines, designed to quickly and efficiently transport natural gas from its origin to areas of high demand.

The Pohokura field, offshore from Taranaki, is the country’s largest natural gas resource, owned by a joint venture between Shell, Todd Pohokura, and OMV New Zealand. The production station is operated by Shell Exploration NZ which uses the services of Shell Todd Oil Services (STOS). The Pohokura field natural gas is fed into the national grid network. The first commercial gas flowed from three onshore ‘extended reach’ drilling wells in the Southern part of the field in September 2006. In March 2007, gas and condensate began to flow from the first of five offshore wells via an undersea pipeline back to an onshore production station at Motunui.

Developing an unmanned site— where operations are monitored from a control room in New Plymouth— required the combined expertise of engineers, consultants and systems integrators. The Pohokura design contractor, Transfield Worley, appointed long-standing systems integrator partner Engineering Control Limited (ECL). One of the requirements for remote operation was that the motor control centres

(MCCs) be integrated into the main plant control system on an intelligent network so that the information from the gas station could be fed back to the control room. Transfield Worley based the new system on the DeviceNet

network together with the Allen-Bradley® ControlLogix® platform from Rockwell Automation®.

Another requirement was that the status of power switchgear at the 400V MCCs and the plant 11kV main switchboard had to be available in the control room and this switchgear had to be operable from the control room as well. This was achieved by hardwiring the switchgear to discrete I/O in the ControlLogix. Being able to operate the switchgear from remote is also a welcome safety feature as it removes the need for local operation and so does not expose operators to possible harm from such things as arc flash as may occur if there is a switchgear fault or failure whilst it is being operated.

Establishing a remote operation

Pohokura produces over 45 per cent of New Zealand’s natural gas which is reticulated around the North Island to industry and domestic consumption. “By using Shell’s technical expertise we set out to deliver a highly reliable unmanned gas production station with a small environmental footprint,” said Paul Brown, Pohokura Operations Engineer. “A priority for us was

to deliver the project on time, on budget and safely, with no harm to personnel or any adverse effects to the neighbours or the environment.”

The operational philosophy for the Pohokura production facility

was to establish an unmanned site with zero normal operating presence (ZNOP); plant operation would be performed off-site from a remote control room in New Plymouth using a Distributed Control System (DCS). Remote operation is an ideal way to help keep personnel safe and away from potentially hazardous equipment, but its operational success relies on excellent control, fault diagnostics and network capabilities.

“DeviceNet provided a network solution that could help provide reliable communication and also had the added feature of Automatic Device Replacement (ADR), allowing for reduced downtime with automatic download of device parameters,” said Prasad Nory, Industry Manager, Rockwell Automation. ADR consists of configuration and auto-address recovery which effectively lowers maintenance requirements. Operating 24 hours a day, 7 days a week, Pohokura has a scheduled proactive maintenance day every month to identify and deal with potential problems. .

The Pohokura blueprintThe Transfield Worley electrically

engineered design was the basis for

STORYAPPLICATION

“By using Shell’s technical expertise we set out to deliver a highly reliable unmanned gas production station with a small environmental footprint.”


a completely integrated solution that required the capabilities of leading board builders, Switchbuild Ltd. The Pohokura solution evolved around the development of two low-voltage MCCs. Two 2.5MVA transformers feed into the first low-voltage MCC via 4000A Air Circuit Breakers (ACBs). Power from the first MCC is then fed through to the second low voltage MCC. The intelligent MCC design utilised the DeviceNet network, communicating to the DOL start motor starters for control and monitoring. The E3 plus smart overloads provided motor protection that very closely matched the motor operating characteristics with the enhanced protection capabilities such as earth fault, stall, thermistor and loss of load that are normally provided by much more expensive motor protective relays.

An Allen Bradley ControlLogix Programmable Automation Controller is used to provide the comprehensive monitoring and control of the MCCs and feeds back information to the distributed control system. “The Allen Bradley solution provides advance load protection. The client has the ability to analyse the performance of their motors and view faults, all in an integral unit that is visible from the distributed control system,” said Donald Liddell, Manager, Switchbuild.

To avoid costly downtime at Pohokura, ECL developed and incorporated switching Controls in the PAC in the event that power is lost from one of the two 11kV incomers. According to Peter Huitema, Engineer ECL, “Normally when supplies switch over you lose power, even if it’s just a few milliseconds, the motors will shutdown. To avoid this, we determined how many seconds the motor can be with no power without causing any damage. We used inertia to keep motors running for up to 1.5 seconds, to allow time for the other supply to switch over. By programming this information into the Control System we were able to avoid costly shutdowns.”

Environmental excellenceThe implementation of state-of-

the-art engineering has enabled the Pohokura plant to be operated remotely. “Safety to personnel and the environment take an even higher priority in a remote operation so plant and components must work reliably with minimal maintenance. All components chosen for the Pohokura project had to have proven reliability,” said Paul Brown, Pohokura Operations Engineer.

To achieve environmental excellence, modifications were made to the original design of the field. Horizontal directional drilling technology was used to eliminate the need to have a pipeline from the onshore production station out to the offshore platform that would have run over the cliff face and across the foreshore. Instead—and as a first for New Zealand—a pipeline was inserted behind the cliff face and underneath the foreshore, so there was no visible or physical intrusion and the local coastal environment was preserved.

The plant’s processing areas are built in concrete bunds. Before the water is drained into the stormwater

treatment systems, an absorbent skimmer removes residual floating hydrocarbons. Stormwater is further processed via a specially designed “wetland” where plants are utilised as a natural bio-filter. Filtration through the wetlands removes any residual hydrocarbons. These environmental features resulted in Shell Pohokura receiving a sustainable development and technical innovation award from the Taranaki Regional Council in 2010.

Reaction to the integrated automation control solution from Rockwell Automation has been positive. “There have been no problems with the PACs from Rockwell Automation in the five years of Pohokura operation—our objectives have been fully satisfied in terms of budget, timing, personnel safety and environmental sustainability,” concludes Brown. The value of the successfully operating remote control operation at Pohokura has been realised and as such, is currently undergoing an expansion to create another plant using the same easily extendable solution provided by the Rockwell Automation Integrated Architecture® system.

Pohokura field is New Zealand’s largest natural gas resource


INNOVATIONSOEM

Customers of machine builders demand solutions that increase business agility, optimise pro-

ductivity and achieve sustainable objectives – while lowering the total cost of ownership. Machine builders, therefore, must differentiate themselves amid global competition and rapidly evolving technology while meeting cus-tomers’ needs.

Original equipment manufacturers (OEMs) Guangdong Yeudong Mechanical Industry Co. Ltd. and Hoong-A Corporation have done just that. The companies have teamed with Rockwell Automation on the design of their respective machines, resulting in products that have reduced programming, minimised installation and startup time, and simplified repair and maintenance.

The Guangdong Yuedong Mechanical Industry Co., Ltd., headquartered in Shantou City in China’s Guangdong province, designs machinery for the food, beverage, dairy and packaging industries. The company sells its products in more than 20 Chinese provinces and exports them to over 70 countries and regions including the Americas, Europe, Southeast Asia and the Middle East.

The company’s CSL-C30 Gable Top Packaging Machine is driven by an Allen-Bradley® PowerFlex® 40 AC drive with an attached single-turn absolute encoder. With each complete turn of the motor, a packet of product is produced. All servo drives synchronise with the main motor in a master/slave relationship, and all axes use compact MP-Series™ low-inertia servo motors. A Rockwell Automation® Kinetix® Integrated Motion System controls motion for the in-feed conveyor, turret indexer, main conveyor, servo filler and servo lifter.

The single-lane machine has a single-servo filling head. Its bottom-up filling system regulates flow to reduce

turbulence and prevent foam. A servo-control carton lifter syncronises with the product fill-flow rate.

The CSL-C30 is controlled by a Rockwell Automation CompactLogix™ programmable automation controller (PAC), a Kinetix Integrated Motion System and RSLogix™ 5000 programming software. The controller carries out discrete, drive and integrated motion control. It sequentially controls the packaging machine and, through SERCOS interfaces, integrates with a Kinetix 6000 system for multiple axis control.

The RSLogix 5000 software’s integrated motion instruction set eliminates the need to write and coordinate two programs on different controllers. It also simplifies the application programming and enhances system performance.

Hoong-A Corporation, South Korea, makes packaging machinery for pharmaceutical and non-pharmaceutical use. In order to meet the specific needs of each client, the company custom-builds machines, including its smartline product for small- and medium-sized batch production. The machine features a balcony-style structure with a highly accurate web transport system for pharmaceutical blister packaging in thermoforming and cold forming. Key elements include the HM 300P blister and HC 200 cartoner, which deliver an output of 300 blisters and 200 cartons per minute.

The blister machine is configured

around an Allen-Bradley CompactLogix™ 5370 L36ERM PAC, Kinetix 5500 servo drive and the Stratix 2000™ unmanaged network switch for the Device Level Ring (DLR) topology. A PanelView™ Plus 6.0 HMI graphic terminal is used for smarter machine control and effective operation.

The Kinetix 5500 connects to and operates with the CompactLogix 5370 PAC, supporting Integrated Motion on EtherNet/IP™. The drive helps minimise machine footprint and simplifies system wiring.

The control system for the HC 200 cartoner is based on the CompactLogix 5370 PAC, Kinetix 5500 servo drive for 1-axis motion and Kinetix 350 single-axis EtherNet/IP servo drive. Leveraging a single network, EtherNet/IP simplifies the integration of the system including HMI, PAC, I/O and motion.

These innovative machines from Guangdong Yeudong Mechanical Industry Co. Ltd. and Hoong-A Corporation help these companies lower their Total Cost to Design, Develop and Deliver® products. More importantly, the machines help their customers to operate with greater speed and accuracy – and shortened lead times.

For more information about OEM solutions, visit:

www.rockwellautomation.com/rockwellautomation/solutions-services/oem/overview.page?. AT

Machine Builders Improve Equipment PerformanceRockwell Automation helps OEMs customise their machines.

Get IP. Get the advantageGet the power of standard, unmodified Internet Protocol (IP) working for you, and open up new opportunities for productivity, efficiency and flexibility.

Providing expert guidance, detailed information and acknowledged best practice, Industrial IP Advantage helps you to unlock the potential in today’s communications technologies. This enables you to improve performance and reduce costs.

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FOCUSPARTNER

System integrators are invaluable to our business: Rockwell AutomationRockwell Automation continues to deliver an industry leading System Integrator program built on the three pillars of trust, collaboration and value

In an increasingly competitive global marketplace, leveraging technology to help sustain profitable business growth is a focus for many companies. According to Darryl Kaufmann, market access manager for Australia and New Zealand at Rockwell Automation, “Our System Integrator program is based on a pro-active relationship between Rockwell Automation, our distributor and the System Integrator. This unique relationship helps drive strategy as well as a technical understanding of our solutions and should assist the System Integrator solving production challenges. Furthermore, the System Integrator has better access to our entire PartnerNetwork including our Encompass Partners. The program offers system integrators the chance to continually enhance competencies and capabilities across multiple disciplines including, control, process, information, and safety. The Recognised System Integrators are resources that are best positioned to reduce project risk when leveraging our

technologies. Solution Partners possess those same traits, but they differentiate themselves with a capability that is unique and specialised, with the ability to deliver across a broad geography. “In return, we offer our Recognised System Integrators and Solutions Partners the opportunity to increase market awareness, expand into new market sectors and improve technical competency and functional excellence. We work closely together with shared commitment and behaviours for customer success,” said Kaufmann. Rockwell Automation develops proactive and mutually strategic relationships with system integrators and acknowledges that integrators play a particularly important role in the Australian and New Zealand region. According to Mauro DelleMonache, marketing director at Rockwell Automation, “In other locations with larger volumes, system integrators tend to develop a more specific industry or application expertise but in our region system integrators tend to work in a

variety of different industries.” “Our architecture is a framework of technology that is most useful when an integrator has applied their methodologies and engineering to make the product of value to the customer. Integrators are absolutely vital. Without a successful integration network we would not be successful in Australia and New Zealand,” said DelleMonache. AT

Our partners, your success.Distinguished system integrators who know your business.Solution Partners and System Integrators, as part of our PartnerNetwork,™ o� er di� erentiated skills and experience in the

areas of control, process, power and information. They can help design, implement, manage and maintain your automated

systems and keep your facilities operating at optimum e� ciency.

For more information, go to: www.rockwellautomation.com/go/tjsiPartnerNetwork is a registered trademark of Rockwell Automation, Inc. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Put our advanced technologies together with the expertise of our Solution Partners, and you have a unique

resource to call on.

“We have a long history of partnering. It is fundamental in our DNA. We see it as the best way to address customer needs.Our approach to partnering is based on an understanding that no single supplier can do it all and a belief in the importance of working with best of breed companies to bring innovation, global reach and local responsiveness”

— Keith NosbuschChairman and CEO, Rockwell Automation

FOCUSPRODUCT


Universal Disconnect Switch Simplifies Design

The new Allen-Bradley® Bulletin 1494U visible-blade disconnect switch provides capabilities for applications with 30, 60 and 100 amps. Rockwell Automation® will be rounding out the Bulletin 1494U line in the next year, with ratings up to 600 amps. The Bulletin 1494U visible-blade disconnect switch provides visible confirmation that the switch is in the “on” or “off” position as it isolates motors, motor controllers and other loads from a supply circuit. The switch offers flexibility covering all applications, thereby reducing needed inventory. Users can choose from a number of styles and options to meet their specific application needs, including nonfusible or fusible versions, and the fusible version provides short-circuit protection.

For more information, visit: http://ab.rockwellautomation.com/Circuit-and-Load-Protection/Discon-nect-Switches/Visible-Blade/1494U-Universal-Disconnect-Switches

HIPERFACE-to-DSL Converter Kit

The new Allen-Bradley® Kinetix® 5500 servo drive converter is designed to convert HIPERFACE feedback to DSL.

With the new converter, users have the flexibility to use a variety of motors with their Kinetix 5500 drive, including any of the HIPERFACE feedback Allen-Bradley MP-Series™ motors and actuators – MP-Series low inertia, MP-Series stainless steel, MP-Series food grade and MP-Series medium-inertia rotary motors as well as the MPAR, MPAI, MPAS and MPMA linear motors.

The converter kit is powered by the drive, which means there is no external power supply. This eliminates parts and installation time. It attaches directly to the drive’s DSL feedback port, simplifying installations. In addition, motor configuration and selection are the same as existing Allen-Bradley Integrated Motion with EtherNet/IP™ servo products, translating into ease of use.

For more information, visit:http://literature.rockwellau-tomation.com/idc/groups/literature/ documents/in/2198-in006_-en-p~a1.pdf

Next-Generation Motor ControlThe Allen-Bradley® E300™ Electronic Overload Relay integrates

communications, including EtherNet/IP™, patented current-measurement technology and I/O options. The modular design – featuring wide current range, multiple sensing capabilities, expansion I/O and operator interface – provides flexibility to tailor the device to user needs.

The relay monitors motor performance, providing diagnostic information on voltage, current and energy; trip/warning histories; percentage thermal capacity utilisation; and time to trip/reset. Operational hours, number of starts and snapshot log are also monitored. In addition, the relay has incorporated the newest technologies directly into the device to help simplify installation and configuration.

A dual-point EtherNet/IP option allows relays to be daisy-chained and eliminates the need for an Ethernet switch. Maintenance personnel can integrate the relay from any Internet-enabled device via a Web browser without the need for special software. The relay supports a DLR network topology to maintain uptime.

For more information, visit:http://ab.rockwellautomation.com/circuit-and-load-protection/lv-motor-protectors/e300-overload-relays

Integrated Display Computers with horsepower

The Allen-Bradley® 6181 Integrated Display Computer form a dynamic portfolio, with Standard, Performance and Advanced Models that provide all-in-one industrial PC options to help meet your application needs. The 6181 models offer an open computing platform with plenty of horsepower to run most client, station and even virtualised software architectures. While the Standard models maintain their original characteristics, the latest generation Performance models build upon the trusted Series E 6181 Integrated Display Computer platform to help provide you with an enhanced user experience and exceptional processing power.

For more information, visit:http://ab.rockwellautomation.com/computers/integrated-display-comput-ers/bulletin-6181

FOCUSPRODUCT


The Kinetix 5500 and VPF Low Inertia Motor Deliver High Performance and Scalability

Rockwell Automation has expanded its Integrated Architecture® system with the Kinetix® 5500 servo drive with Integrated Safety option and VPF Low Inertia servo motor offering. The system is designed to meet the unique needs of many food and beverage applications

The Kinetix VPF Motor connects to Kinetix 5500 drives for simple, optimised motor/drive operation. It adds 63 mm and 75 mm frames to MPF’s available 100/115/130/165 mm frame sizes. It has the same dimensions as the VPL motors for same frame/stack selection.

The motor features food grade, improved white paint; single cable; non-corrosive food grade fasteners and shaft; and food grade shaft seal and grease. It is also REACH and RoHS-compliant.

Platform options include optional lower speed windings, allowing for optimised system sizing and costs; holding brake/non-brake; and multi-turn/single-turn feedback.

The servo drive and motor reduce system cost and inventory. What’s more, the combination is energy-efficient, providing up to 50 percent less energy usage with proper system sizing. In addition, lower speed windings allow for lower current, a smaller drive and smaller gauge cables. Furthermore, the system minimises installation errors with a well-shielded cable clamp design and simplifies mounting, as there is no backplane or power rail required.

For more information, visit:http://ab.rockwellautomation.com/motion-control/kinetix-5500-servo-drive

Software Drives Automation Productivity

With the Rockwell Software Studio 5000 Logix Designer v24 software engineers have new design capabilities that can dramatically increase automation productivity, improve start-up time and reduce costs throughout a project’s life cycle. Latest additions include an application-centric view of code, enhanced work flows for more efficient re-use of content, and new collaborative tools that make it easier for multiple people to work together.

The Studio 5000 Logix Designer v24 software is used to configure Allen-Bradley Logix5000 controllers, for discrete, process, batch, motion, safety and drive control.

In addition, the Studio 5000 Logix Designer v24 software supports the Allen-Bradley Kinetix 5500 servo drive with integrated safety to help machine builders

reduce development and installation time. It also provides support that allows the Allen-Bradley PowerFlex 527 AC drive to be the first variable frequency drive to exclusively use the motion instruction sets within the Studio 5000 Logix Designer v24 software for machine control and motor synchronisation.

For more information, visit:http://www.rockwellautomation.com/rockwellsoftware/products/studio5000-logix-designer.page?utm_source=Marketing&utm_medium=PublicRelations&utm_content=Studio5000_NewsRelease_November182014&utm_campaign=IA_NA_XX_English_2015

Make more use of the data you already collect

The new FactoryTalk® VantagePoint EMI software offers real-time production information in a dashboard, trend, report, or key performance indicator (KPI) on a mobile device or computer web browser. Now decision makers can be notified when production parameters move outside their pre-set limits. This enables informed decisions, utilising real-time data, on mobile devices or desktops to become a standard process in your improved operations. Preparing simple reports no longer requires hours or days spent collecting relevant data from disparate systems, which then must be routed and analysed before production decisions can be made.

Only FactoryTalk® VantagePoint EMI organises, correlates, and normalises disparate data from your manufacturing and production processes and business systems in a Unified Production Model (UPM). It then enables you to organise and present information in everyday language — tailored to users’ needs on mobile devices or desktops.

FactoryTalk VantagePoint EMI helps solve many of the delays associated with typical manufacturing reporting. By organizing all data sources in a Unified Production Model, bridges are created between multiple systems, vendors and data types. Data in the model can be accessed from anywhere, by anyone in real world terminology. This data can then be presented as information relevant to the user’s role and responsibility within the organisation.

For more information, visit:http://www.rockwell-automation.com/rock-wellsoftware/products/factorytalk-vantagepoint.page


NEWS / CALENDAR

VISIT ROCKWELL AUTOMATION AT THESE EVENTS: FEBRUARY – APRIL 2015

DATE EVENT LOCATION

Auto-Bake is delighted to announce that it has been Highly Commended for manufacturing excellence in the Manufacturing Export Awards category of the Premier’s NSW Export Award. The Premier’s NSW Export Awards aims to recognise excellence in the export of goods and services by NSW business. The Awards acknowledge the important contribution of businesses to the economy through job creation and increased prosperity for the community and for the state.Auto-Bake is a global designer and supplier of fully automated industrial baking ovens and systems. The company has been a commercial baking innovator for more than fifty years delivering customised, fully automated production lines that are renowned all over the world. Founded in Australia, Auto-Bake has now become a truly global operation, servicing North America, Europe, Asia and the Middle East. According to Amanda Hicks, CEO at Auto-Bake, “This award acknowledges the contribution of our wonderfully talented team whom have built our company’s reputation by providing unique solutions to the world’s largest food producers.” “More broadly we recognise that

this success can only be sustained if the innovation momentum is maintained. Therefore in addition to our own resources we ensure that we are aligned with and integrate the latest development from our key suppliers such as Rockwell Automation to ensure we can meet the new opportunities wherever they arise,” said Hicks. As a Rockwell Automation Machine Builder Partner, Auto-Bake’s world-renowned products utilise the company’s industry leading industrial automation technology. Auto-Bake provides not only the baking system or hardware but also the software and installation support. The company has adapted its unique Serpentine technology to meet the needs of the world’s major food manufacturers. According to Jacqueline Las Pinas, account manager at Rockwell Automation, “We are proud to be associated with Auto-Bake because they are an innovative company that incorporates the latest technology advances in their products.” “At Rockwell Automation we are

committed to delivering products and solutions to help Auto-Bake achieve machine control excellence. Through our global presence we are able to work with Auto-Bake to extend superior service and support to customers worldwide,” she said.

About Auto-BakeAuto-Bake is a global designer and supplier of ovens and baking systems. Based on the company’s innovative Serpentine® baking technology, Auto-Bake continuous baking systems are custom-designed to meet the needs of a diverse range of baking applications, including the production of cakes, muffins, cookies/biscuits, pies, desserts, and bread and proofed products.

Auto-Bake’s international success recognised by Manufacturing Export Awards

Integrated Architecture™ Tools: EtherNet/IP Capacity Tool The EtherNet/IP™ Capacity Tool can help you in the initial layout of your EtherNet/IP network by calculating resources (nodes and packets per second) used by a network. This allows you to determine the feasibility of your network in just a few minutes. Download this software utility from the Integrated Architecture Tools web site to assist with the design of your next project.

The EtherNet/IP Capacity tool are available on the IA Tools site: www.ab.com/go/iatoolsIntegrated Architecture is a trademark of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA.Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. AD2014-48-EN

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